Prefabricated wall structure elements and assembly thereof



APril 8, 1969 J. H. ROTHERM-EL 3,436,885

PREFABRICATED WALL STRUCTURE ELEMENTS AND ASSEMBLY THEREOF Filed Dec.14, 1966 Sheet g of 3 240 28 24b 38 60 [3am April 1969 J. H. ROTHERMEL3,436,885

PREFABRICATED WALL STRUCTURE ELEMENTS AND ASSEMBLY THEREOF Filed Dec.14, 1966 Sheet 5 of5 United States Patent 3,436,885 PREFABRICATED WALLSTRUCTURE ELEMENTS AND ASSEMBLY THEREOF John H. Rothermel, Lake George,N.Y., assignor t0 Integral-Structures, Inc, a corporation of New YorkFiled Dec. 14, 1966, Ser. No. 601,649 Int. Cl. E041) 1/04; E06b 3/54 US.Cl. 52207 11 Claims ABSTRACT OF THE DISCLOSURE This invention relates tobuilding construction and more particularly to a novel set of wallelements which may be fastened together to form a wall structure.

In the art of building light commercial buildings, common constructionincludes light metal framing, such as aluminum framing, large wall panelareas of glass and other panel areas of a lightweight translucentmaterial. Such buildings are typically used to house service stations,hamburger stands, small business establishments and light duty publicbuildings and the like. Typically building the wall panels of suchbuildings requires the use of the usual building trade skilled craftsmenand the necessary tools which are utilized by such craftsmen in cludingsaws, hammers, devices for driving and securing threaded fasteners andthe like.

This invention is directed, in brief, to the provision of a plurality ofinterlocking engageable wall members which serve as frames forcaptivating different wall panels and which fur ther may be lockedtogether to form a common integral wall held together by interfittingparts without the need for common fastening elements such as bolts,screws, nails, and the like.

It is a primary object of this invention to provide a novelprefabricated wall assembly for use in light commercial buildings.

It is another object of this invention to provide a novel prefabricatedwall assembly wherein the several elements of the wall may beinterlocked together by interfitting 0 parts, eliminating the need forconventional assembling tools and construction equipment for assemblingand erecting such a wall.

It is a further object of this invention to provide a prefabricated wallassembly of interlocking parts which is easily erectable byunprofessional, semiskilled labor.

It is still a further object of this invention to provide aprefabricated wall assembly comprising intertfitting, interlocking partswhich may be disassembled and reerected without damage or deteriorationof any of the components.

Yet a further object of this invention is to provide a novelprefabricated wall assembly of interlocking, interfitting parts whichmay be easily assembled in any type of weather condition.

Still a further object of this invention is to provide a set ofprefabricated wall members including interfitting elements which may belocked together to provide wall units for containing different types ofwall panels, the several wall units being capable of being lockedtogether by different prefabricated members.

3,436,885 Patented Apr. 8, 1969 Other objects, features and advantagesof the present invention will be apparent from the following descriptionof the preferred embodiments illustrated in the accompanying drawings,in which:

FIGURES 1-15 are section views of the several prefabricated interfittingwall elements of this invention which may be utilized to form wall frameunits which secure wall panels of different characteristics, the severalwall units formed thereby being capable of being locked together by someof the members shown in FIGURES l-15 to form an integrally connectedcommon wall;

FIGURE 16 is a fragmentary, broken, generally horizontal section viewthrough a wall assembly utilizing some of the prefabricated wallelements shown in FIG- URES 1-15;

FIGURE 17 is a continuation of the wall shown in FIGURE 16;

FIGURE 18 is a fragmentary section view of a portion of a wall assemblyusing the wall elements shown in FIGURE 14 and illustrating a'threadable locking means for drawing two wall units together;

FIGURE 19 is a fragmentary vertical section view showing therelationship between horizontal wall elements illustrated in FIGURES l,2 and 15 and a wall supporting surface;

FIGURE 20 is a fragmentary vertical section view showing wall elementsfrom FIGURES 3 and 15 in use in tying portions of the wall to asupporting surface;

FIGURE 21 is a fragmentary sectional view similar to FIGURE 20 showingyet a different arrangement of elements from FIGURES 13 and 14 in use intying the wall to a supporting structure; and

FIGURE 22 is a fragmentary section view showing the utilization ofelements illustrated from FIGURES 13 and 14 in use in the top of a wallline adjacent the roof line of a building.

Referring now to the drawings, in FIGURE 1 there is shown a section viewof wall element 10 which may be utilized for forming frames forcaptivating different wall panels. Preferably the element 10, and allother elements to be described, are made of relatively hard, slightlyresilient material, such as extruded aluminum. Element 10 is intendedfor use as a thin panel frame member or window frame or window mullion,it being understood that this member could be used as an upright memberand also as a horizontal member, forming the sides of a framework whichserves to captivate a relatively thin panel such as a windowpane or thelike. Window frame mullion 10 includes a generally fiat panel receivingsurface 12 which is flanked by a pair of grooves 14a and 14b, generallyU-shaped in section, which, in turn, are flanked by fiat wall portions16a and 1612, respectively, generally coplanar with the panel receivingsurface 12. Grooves 14a and 141) have opposed splines 14a and 14b,respectively. Each of wall surfaces 16a and 16b terminates in a rightangularly or rearwardly extending side wall 18a and 18b, respectively,which terminate in inwardly returned portions 20a and 20b, respectively,generally parallel to, and spaced from, portions 16a and 16b. Eachinwardly returned portion 20a and 20b terminates in an inwardly spaced,rearwardly extending portion 22a and 22b, respectively, each of which isparallel to and inwardly spaced from, side walls 18a and 1812,respectively. Locking fingers 24a and 24b project outwardly from each ofthe portions 22a and 2211, respectively, each of said locking fingersbeing generally parallel to and closely spaced from the surfaces 20a and20b and terminating short of the line defined by a continuation of sidewalls 18a and 18b. One face of the fingers 24a and 24b is provided witha small notch such as 24a and 24b for receiving a generally matingspline of a locking member (to be described later) which is inserted inspace 25a and/or space 25b between each of fingers 24a and portion 20aand finger 24b and portion 201), respectively.

Panel retention mullion 27 is illustrated in FIGURE 2. This mullionincludes an outer surface 27a, a first panel retaining portion orsurface 27b, and a second panel retaining portion or surface 270, eachof which extends outwardly from the same side of opposite ends ofsurface 27a generally parallel to each other. Portion 27c termimates ina returned portion 27d which extends generally normal to portion 270 andgenerally parallel to surface 27a. Portion 27d, in turn, terminates inlocking finger 272 which is generally parallel to portion 27c and theadjacent longer finger portion 27 of portion 27b. Each locking fingerincludes opposed grooves 27g generally of a size and location to engagesplines 14a and 14b of grooves 14a and 14b to retain the retainingmullions 27 therein with either portions 27b facing each other to retainthick panels therebetween or portions 270 facing each other to retainthin panels therebetween. Cushion .means in the form of a thin,tape-like strip may be applied to either surface 27b or 270 to serve asa cushion when retaining panels such as windowpanes between retentionmullions 27.

Shown in FIGURE 3 is a panel edge member or frame member or enlargedpanel retaining mullion 28. This member is generally U-shaped in sectionand includes a panel receiving surface 30 generally flanked by twooutwardly extending side wall members 32a and 32b which extend outwardlyfrom the same side of each end of the face 30 generally parallel to eachother. The cross sectional thickness of mullion 28 is generally the sameas that of mullion and the distance between interior and exterior ofside wall members 32a and 32b is substantially the same as the distancesbetween the corresponding portions of side Walls 18a and 18b of mullion10.

The opposite side of panel receiving surface 30 includes rearwardlyextending portions 34a and 34b which are generaly parallel to themembers 32a and 32b, respectively, spaced inwardly therefrom the samedistance as portions 22a and 22b are spaced inwardly from side walls 18aand 18b. Locking fingers 36a and 36b extend laterally from portions 34aand 34b, closely spaced from, and generally parallel to, the adjacentportion of the panel receiving surface 30 approximately the samedistance as locking fingers 24a and 24b are spaced from portions 20a and20b. In like manner, locking fingers 36a and 36b are provided withlocking grooves 36a and 36b for receiving splined surfaces of a lockingelement in spaces 37a and 37b, respectively, to look similar panelstogether.

For example, if a mullion 28 is turned. so that the portions 34a and 34babut portions 22a and 22b of .mullion 10, the two sets of lockingfingers 24a and 36a and 24b and 3612 would be in a position to receive agenerally U-shaped locking member to lock mullions 10 and 28 together.This, in fact, is one of the intended uses of the two members and forthis purpose, the locking element or locking mullion 38, shown in FIGURE4, is provided.

Locking mullion 38 is generally U-shaped and includes a base portion orside wall portion 40 and two parallel spaced outwardly projectinglocking legs 42a and 42b each being of a size to snugly fit in thespace, such as 25a or 37a, between a locking finger, such as 24a or 34a,and its companion wall surface 20a or 3011, respectively. In addition,each of the legs 42a and 42b includes a mutually inwardly facing rib orspline portion 42a and 42b, one of which is intended to occupy one ofthe grooves such as 24a of one of two mullions, such as 10 and 28, whenabutted together, the other of which is intended to occupy the other ofthe grooves, such as 36a, to thereby lock the two mullions as a unit. Inaddition, the length of legs 42a and 42b is intended to be generallycoextensive with the offset distance of the portions on which thefingers are supported, such as 22a or 34a, so that the portion 40 of thelock mullion 38 will be a general continuation of the side Wall Surfaceafforded by 4 side walls, such as 18a and 18b or 32a and 32b. Finally,the cross sectional thickness of legs 42a and 42b is about the same asthe width of spaces 25a, 25b, 37a, 37b, and the like.

The lock member or lock mullion 44, shown in FIG- URE 5, may be usedinstead of the lock mullion 38 where it is desirable or necessary tolock two mullions together farther apart than permissible with mullion38. Lock mullion 44 is a generally U-shaped structure having a base orside wall portion 45 and two spaced, parallel, outwardly extending legs46:: and 46b, each of which, in the interior thereof, is provided with aspline 46a and 46b which may engage companion notches in the fingers inthe same manner as described with reference to mullion 38.

Next shown in FIGURE 6 is a cap or edge member or cap mullion 48 whichis generally U-shaped in section including a base portion 49 and twospaced, parallel, forwardly extending side wall portions 50a and 581),said portions being spaced apart generally the same distance as theaforedescribed similar portions 18a and 18b on mullion 18 and 32a and32b on mullion 28.

The side wall portions 50a terminate in rearwardly extending andslightly inwardly offset fastening fingers 52a and 52b, respectively,each of which is provided with a splined portion 52a and 52b on theoutwardly facing wall surface thereof. The portions 52a and 52b areinwardly offset a distance generally corresponding to the mullion crosssectional thickness so that they will generally matingly engage theinterior of the wall surfaces such as 32a and 32b. In the case of themullion 28, such engagement would be possible with the splines 52a and52b occupying the grooves 32a and 32b on the interior of the side walls32a and 32b, respectively, of mullion 28. In this fashion, mullion 48would be fastened to mullion 28, providing a cap therefor by means ofthe surface portion 49.

In FIGURE 7 there is shown a corner member or corner mullion 54. Cornermullion 54 is a right-angular structure including a first wall portion56a and a second wall portion 56b extending generally perpendicularlyfrom one end of wall portion 56a. Both portions 56a and 56b aregenerally coextensive in length, each being provided with a generallyperpendicularly inwardly extending locking finger 58a and 58]),respectively, spaced inwardly from the free end of each wall portionsubstantially the same distance. Each locking finger 58a and 58b isprovided with a small splined portion 58a and 58b, respectively, facinginwardly or toward the other wall of the mullion. Each finger 58a and58b is spaced from the corner formed by the juncture of the two walls adistance substantially equal to the width of the several mullion membersdisclosed herein such as mullions 10, 28 and 48, which have already beendescribed. When it is desired to join two right angularly disposed wallsections, mullion S4 is utilized with finger 58a engaging a finger suchas 24a or 36a on the mullion of one wall along the outer edge thereofand with the finger 58b engaging a finger such as 24b or 36b on theouter edge of the mullion of a wall disposed at generally right anglesto the first wall. This connects the two walls together and provides amask or cap for the corner juncture of the two walls.

Shown in FIGURE 8 is the door jam-b member or door jamb mullion 60. Thismullion includes side walls 62a and 62b extending outwardly from theends of wall surface 64 generally parallel to each other so that the twoside walls are spaced apart a distance substantially the same as orslightly more than, the distance between the interior of side walls 32aand 32b 50 that door mullion maybe snugly received between the interiorof the side walls such as 32a and 32b of mullion 28 to be securelynestably held therein. Surface 64 is provided with an outwardlyprojecting portion 66 which serves as the door jamb against which theedge of a door may rest. Side wall surfaces 62a and 62b terminate ininwardly extending portions 68a and 68b which are generally parallel to,and spaced from, wall 64. These wall portions 68a and 68b, in turn,terminate in rearwardly trailing parallel portions 70a and 7012, each ofwhich has a splined outer portion 70a and 70b.

Shown in FIGURE 9 is the window frame member or window mullion 74 whichis similar to mullion 10. Mullion 74 includes a panel receiving surface76 and two lock member receiving grooves 78a and 7812 on either side ofsurface 76.

Each of the grooves 78a and 78b is splined at the opposite sides of thegroove as at 78a and 78b, respectively. On either side of the groovesthe wall portions 80a and 80b extend generally coplanar with the centralpanel receiving portion 76.

Fingers 82a and 82b extend rearwardly from portions 80a and 80b,respectively, generally parallel to each other from a point near thefree end of each wall portion 80a and 80b. It is intended that thedimension across mullion 74 would be generally the same as that acrossmullions 10, 28 and 48 while the fingers 82a and 82b would be set infrom the ends of the portions 80a and 801: a distance substantiallyequal to the thickness of the several extrusions disclosed herein. Eachof the fingers 82a and 82b is provided with a splined outwardly facingsurface 82a and 82b for locking engagement with a mating grooved surfaceof another member, such as the grooves 32a and 32b in the lockingmembers 32a and 32b of mullion 28. Thus, by assembling mullions 74 and28 together, one would arrive at a mullion assembly similar to themullion 10, suitable for use as a window or similar panel frame.

Takeoff plate or takeoff mullion 84 is illustrated in FIGURE 10. Mullion84 is a generally planar structure substantially coextensive in widthwith the width across the mullions 10, 28, 48 and 74. This mullionincludes a base portion 86 and two rearwardly extending portions 88a and88b, each of which is set inwardly from the ends of the base portion 86a distance substantially the same as the portions 34a and 34b on mullion28. In addition, each portion 88a and 88b includes an outwardlyextending finger 90a and 9012 which is generally parallel to, andclosely spaced from, the base 86 substantially the same distance asfingers 36a and 36b on mullion 28, providing a space 91a and 9112,respectively. Each finger 90a and 90b is grooved or notched at 90a and90b so that the takeoff plate 84 may be fastened to mullion or mullion28 by means of the locking mullions 38 or 44 as disclosed herein.

Takeofi plate 84 is substantially the same as the rear wall portion 30of mullion 28 without the side walls 32a and 32b. The intended use ofthis mullion is, as shown in FIGURE 16, where it is desired to run awall course offset from the main wall courses, the takeoff plate ormullion 84 may be secured by means such as threaded fasteners 92 to theexterior of the wall and, with the aid of the locking fingers 90a and9012, a similar prefabricated wall may be run from the point of takeoff.

Common panel mullion or common panel joiner 96 is illustrated in FIGURE11. Mullion 96 is generally H-shaped in section, including a cross-bar98 and side wall members 100a and 1020 which extend forwardly andrearwardly from one end of bar 98, and side wall members 1001) and 10212which extend forwardly and rearwardly from the opposite end of crossbar98. The dimension across the exterior of mullion 96 is the same as thatwith mullions 10, 28, 48, 74 and 84. The dimension between the interiorof the pairs of side wall surfaces 100a, 1001) and 102a and 102]; is thesame as the dimension between similar surfaces in mullion 28 and alsothe same as the outer dimension between side walls 62a and 62b ofmullion 60 as well as the outer dimension between fingers 82a and 82b ofmullion 74. The interior of each of the side walls 100a, 10Gb and 102a,1021: is provided with a groove 100a, 1001) and 102a and 1021),respectively, so that mullion 96 may snugly receive the door jambmullion 60, engage fingers 6 82a and 82b of mullion 73, or engage thefinger portions 52a and 52b of mullion 49.

Shown in FIGURE 12 is the end cap or end mullion 104. End mullion 104 isgenerally U-shaped in section and includes a base portion 106 andoutwardly extending parallel side walls 108a and 108b, spaced apartgenerally the same distance as corresponding elements of mullions 96,84, 74, 48, 28 and 10. Each side wall 108a and 1081) is grooved on theinside thereof as at 108a and 10817. Thus the end cap mullion 104 may bematingly engaged with window frame mullion 74 or mullion 49 to enclosethe rear of the same. In addition, door jamb mullion 60 may befrictionally held between the interior of fingers 108a and 1081) ofmullion 104.

Further included as part of the wall structure elements of thisinvention is transom means or horizontal rail 110, shown in FIGURE 13.Rail 110 includes a base portion 112 of reduced width relative to thepreviously described mullions. Forwardly extending and inwardly turnedspaced side walls 114a and 11411 extend outwardly in one direction fromopposite ends of base 112. Side walls 116a and 1161) extend outwardlyfrom the opposite face of each end of base 112, generally parallel toeach other. At the free end of side walls 116a and 11612, a sealretention leg 118a and 118b is provided, spaced generally inwardly fromthe outside of walls 116a and 116b, respectively. Each seal retainingleg 118a and 11812 is provided with a seal retaining cavity 120a and1201;, respectively, for receiving a resilient sealing member. Theintended use of the transom member 110 is as a horizontal beam member,such as adjacent the supporting base for the wall structure or adjacentthe roof structure which might cover the enclosure defined by the wallstructure comprised of the prefabricated elements of this invention.

Another horizontal beam member or transom member is the aligning rail orpanel head 122 shown in FIG- URE 14. Panel head 122 has a generallyU-shaped configuration and includes a crossmember 124 and two spaced,generally parallel, outwardly extending side walls 126a and 1261:. Theexterior dimension of member 122 is substantially the same as theinterior dimension between the side wall members of mullions 28, 96 and104 so that member 122 can be snugly, matingly received and heldtherein.

Each side wall 126a and 12615 of member 122 terminates in an inturnedhooked end 128a and 128b, respectively. In addition, the face ofcrossmember 124 is also provided with short stubs or projections 130aand 13011 which are in opposition to, and alignment with, the inturnedends 128a and 1281) of walls 126a and 126b. It is intended that thedimension between stubs 130a and 130k as well as inturned ends 128a and128b would be substantially the same as the exterior dimension acrossthe transom member 110 so that member 122 could be snugly, matinglytelescoped over the transom means 110 and securely held thereon.

Another transom member or aligning rail 132 is shown in FIGURE 15.Aligning rail 132 includes a base portion 134 connected by divergingportions 136a and 136b to first generally parallel offset portions 138aand 1381). Second diverging connecting portions 140a and 1401) extendoutwardly from portions 138a and 138b, respectively, each terminating ina seal retention portion 142a and 142b, respectively. Each sealretention portion includes a seal retention cavity 144a and 14417 whichis intended to receive a resilient sealing member so that when transommember 132 is abutted against a roof line or supporting base, the memberwill be in sealing engagement therewith.

Each sealing leg portion 142a and 142b includes a rearwardly extendingside wall portion 146a and 146b, respectively, each of which, in turn,is provided with a groove 146a and 1461) on the interior wall thereof.The dimension between the exterior of side walls 146a and 146b is thesame as the dimension between similar portions of the mullions 28, 48,84, 96 and 104 so that the side walls of the aligning rail 132 will bein alignment with the side walls of any such mullions which may beplaced thereupon.

A composite wall section utilizing the several structural members shownin FIGURES 1-15 together with other panel structures is shown in FIGURE16.

The elements Will be described beginning at the top right hand corner ofthe drawing and proceeding to the left and then downwardly. Mullion 49is utilized as an end cap or cover in engagement with the mullion 96,the splines on fingers 52a and 52b of mullion 48 engaging the grooves inthe interior of side walls 102a and 10212 of mullion 96. The offset offingers 52a and 5212 from side walls 50a and 50b of mullion 48 providesa smooth continuity to the exterior wall surface defined by the junctureof side walls 102a, 50a and 10212, 50b.

The other side walls 100a and 10012 of mullion 96 frictionally embrace awall panel 147 which is held therebetween. Preferably panel 147 is ablock of insulating material, such as an expanded foam plastic, or thelike, generally indicated 147a, which is held between tw thin sheets ofrigid material such as aluminum outer skins 2147b and 1470 which arebonded to the insulating material. It is intended that the exteriordimension across the outside of block 147 should be slightly greaterthan the interior dimension between the side walls 100a and 10012 and ofmullion 96 and similar side walls of other similar mullions so that thepanel may be securely held between the interior of the side walls in aforce fit relationship therewith.

The other end of panel 147 is similarly snugly held between the sidewalls 32a and 32b of mullion 28. This mullion is spaced from the windowframe mullion and secured together therewith by means of two lockmullions 44, the fingers 46a and 46b of each lock mullion 44 occupyingspaces 37a and 37b of mullion 28 and spaces 25a and 25b of mullion 10,thereby engaging the fingers 36a and 36b of mullion 28 and 24a and 24bof mullion 10.

As previously described, the takeoff plate mullion 84 is shown securedby fastening means 92 to the outside wall defined by side wall portions18a of mullion 10 and 32b of mullion 28.

The mullion 10 adjacent mullion 28 is spaced from a second uprightlydisposed mullion 10 and rests on top of a third horizontally disposedmullion 18 (see FIG. 19) defining a window frame, or the like, forreceiving a thin panel or thin windowpane 148. Windowpane 148 is heldbetween the several windowpane lock members 27 that are positioned inthe several grooves 14a and 14b in each of the mullions 10 with portions27c opposing each other for retaining a narrow panel, thereby holdingwindowpane 148 in abutment with the panel receiving surfaces 12 of eachmullion 10 defining the frame. To complete the frame, a fourth mullion10 is extending horizontally would be positioned adjacent the rooflineof the wall.

Another mullion 28 is situated generally at a right angle to theleft-most mullion 10 at the top of FIGURE 16, creating a generally rightangular turn in the wall assembly. Corner mullion or cap 54 is utilizedto secure the corner and mask the rear edges of the right angularlyassociated adjacent mullions 10 and 28 with fingers 58b of mullion 54-in engagement with finger 24a of mullion 10 and finger 58a in engagementwith finger 36a of the right angularly oriented mullion 28. In addition,a right angle brace member 149 may be inserted between the closelyadjacent fingers 24b of mullion 10 and 36b of mullion 28 to secure thetwo together at the interior of the corner.

The side walls 32a and 32b of mullion 28 snugly embrace, in a force fitrelationship, the outer metal skin 14712 and 1470 of the block-like wallpanel 147 to hold the same oriented at a right angle relative to thepreviously described wall structure. The other end of wall panel 147 issimilarly captivated between the side wall members 32a and 32b ofanother spaced mullion 28.

Proceeding along the wall, aligned with previously mentioned mullion 28is a window frame mullion 10. Mullion 18 is connected to mullion 28 bytwo lock mullions 38, the fingers 42a and 42b of each of which occupyspaces 37:: and 37b to interlock with the fingers 36a and 36b of mullion28 and also occupy spaces a and 25b to interlock with fingers 24a and24b of mullion 10. The base surface 40 of lock mullion 38 provides acontinuation of the wall surface between the side wall members 32a and18a of mullions 28 and 10 and the opposite side walls 32b and 18b of thesame mullions.

Again, in the window construction, another upright window mullion 10' isalso spaced across from the first mullion 10 and horizontally disposedmullions 10 are utilized at the top and the bottom to form a frame-likeenclosure with the several grooves 14a and 14b occupied by the windowlock mullions 27. This time, the window lock mullions 27 are reversed intheir orientation with portions 27b opposing each other so that thespace between them is enlarged to accommodate a thickened panel orthickened windowpane 148a which abuts against the panel receivingsurface 12 of the several mullions 10.

The next upright mullion 10 is connected to a mullion 28 by means of alock mullion 38 along either side wall, the fingers 42a and 42b of lockmullion 38 engaging the fingers 24a and 24b of mullion 10 and 36a and36b of mullion 28 with the side wall portions 40 of the mullions 38forming a continuation of the wall surface defined by the side walls18a, 32a of mullions 10 and 28, and 18b and 32b of the same mullions.Mullion 28 mounts the door jamb mullion by snugly retaining, in a forcefit relationship, the outer side walls 62a and 62b of mullion 60 withinthe interior of the side walls 32a and 32b, respectively, of mullion 28.Blocking means such as block 149 may be inserted between mullions 28 and60 to insure that mullion 60 will not be pushed inwardly relative tomullion 28. In addition, the block 149 may beheld by suitable fasteningmeans such as countersunk screw 149a which extends through mullion 60,block 149, and into mullion 28. The door jamb surface 66 of mullion 60is in a position to engage a rear face 150a of a door panel 150 whichpreferably is of a thickness generally corresponding to the offset ofdoor jamb 66 from the outer wall surface so that the front face 15% ofdoor 150 is generally in alignment with the wall surface defined by theseveral side wall portions of the joined mullions; Another upright doorjamb mullion 60 is positioned opposite the first mentioned door jambmullion 60 and retained in the aligning rail 122 which is used toperform a mullion function by gripping the fingers a and 70b of the doorjamb mullion on the interior of the inturned end portions 128a and 12%.Again a blocking means, such as block 159, may be inserted and held bysuitable fastening means (not shown) as described with reference toblock 149 and screw 14912.

A hinge 152 may be secured by means such as threaded fasteners 154 toone edge of door and to a face 64 of the one mullion 60 so that the doormay be pivotally mounted with respect thereto, the opposite edge of thedoor abutting the jamb portion 66 on the opposite mullion 60 therebyproviding a means for gaining access from one side of the wall structureto the other side intermediate the ends thereof.

The vertically disposed aligning rail 122, in serving a mullionfunction, is frictionally retained in 'a force fit relationship in theinterior of the metal skin side walls 147a and 147b which embrace theside walls 126a and 126b, thereby securely mounting the wall panel 147along the course of the wall, it being remembered that the exteriordimension across the aligning rail 122 is substantially the same as theinterior dimension between the side wall portions such as 320 and 32b ofmullion 28 and similar side wall portions of mullions 96 and 104.

FIGURE 17, a continuation of FIGURE 16, shows a continuation of the wallcourse from the broken portion of the previously described wall panel147, with the opposite end of the wall panel having its outer metal skin147b and 1470 snugly received in a force fit relationship between theside walls 32a and 32b of a rnullion 28. This rnullion is, in turn,secured to another window frame structure including an opposite uprightwindow frame mullion 74, as well as horizontal rnullion as previouslydescribed and as indicated in FIGURE 5. Upright mullion 10 closelyadjacent the previously described mullion 28 is secured thereto by meansof the lock mullions 38. A thin panel 148 is secured within the framedescribed by the several window mullions by means of the lock mullions27 which are in the same orientation as shown in the short wall portionat the top of FIGURE 16, and reversed with respect to the orientationshown in the longer wall portion in the middle of FIGURE 16, so thatthey snugly retain the thin panel 148 within the frame defined by thewindow mullions.

Fingers 82a and 82b of windowmullion 74 are frictionally retained in aforce fit relationship to the interior of the side walls 108a and 108bof an end cap mullion104 with the base portion 106 of mullion 104serving to enclose the end of the wall course. It should be understoodthat if a four-sided enclosure were to be created, the several cornerswould be formed in a fashion to that shown at the top of FIGURE 16, but,as illustrated herein, if it is desired to form a wall structure withfree ends, then the mullions 104 and 48 may be used to suitably enclosethe ends and provide a clean appearance thereto.

FIGURE 18 illustrates a means for joining two adjacent panel walls 147.In FIGURE 18, the two panels 147 are each secured in a force fitrelationship to an aligning rail 122 which is used to perform a mullionfunction. As previously described, the outer skins 1471) and 1470 ofeach of the panels 147 snugly embrace, in a force fit relationship, theside walls 126a and 1261;, respectively, of each of the aligning rails122 to join the panels to the rails. The interior 147a of each of thepanels 147 preferably being a light weight expanded foam plasticmaterial, there is nothing inherent in the material 147a itself whichwould permit it to receive conventional fasteners and securely grip thesame. For this reason, holes 156 may be generally centrally bored in thebase portions 124 of aligning rails 122 to receive the opposite threadedfasteners 157A and 15717 for holding locking means 158. Means 158includes two portions 159 and and 1-60, portion 159 including rotatableelement 1590. A workman may first secure one portion, such as 160 to theportion 124 of one aligning rail 122. The next panel 147 may then beabutted in alignment with the first panel 147 and with the portion 159secured thereto, elements 159a is rotated so that it is received inportion 160 thereby snugly drawing the two panels 147 together so thattheir side wall portions 1471: and 1470 form a substantially smooth wallsurface.

In FIGURE 19, the aligning rail 132 is shown supporting a window framemullion 10 which functions in a transom or horizontal beam fashion. Thealigning rail 132 is provided with resilient seal members 156 in each ofthe cavities 114a and 144b for sealing engagement with the horizontalsurface 150a or the floor on which the structure rests. FIGURE 19 isillustrative of how the bottom and top portions of the window framesformed by the mullions 10 are utilized as the horizontal members tocomplete the frame and their relationship with the 'bottom supportingsurface or top wall of the building, or the like, with which the wallstructure is associated. The portions 22:: and 22b of the Windowrnullion 10 rest on top of portions 138a and 13812, respectively, of thealigning rail 132 with diverging portions 136a and 136b of the aligningrail preventing lateral movement of mullion 10 with respect to aligningrail 132 so that the two members are generally held in verticalalignment with the side walls 180 and 18b of mullion 10 generallycoplanar with the portions 146a and 14617 of the aligning rail.

In FIGURE 20, the aligning rail 132 is shown supporting mullion 28 whichis serving a transom or beam function. The mullion 28 embraces, in aforce fit relationship, the metal sides 1471) and 1470 of block-likepanel 147 between the side walls 32a and 32b. The base 30 of mullion 28rests on the base portion 134 of the aligning rail 132, with the fingers34a and 34b abutting portions 136a, 138a, and 1361), 138b, in a similarmanner to that described with reference to corresponding portions ofmullion 10 shown in FIGURE 5, thereby retaining the mullion 28 againstlateral movement with respect to the aligning rail 132.

Rail 132, as shown in FIGURE 20, may be provided with a cross piece 160extending between portions 140a and 14012. Crosspiece is provided withan opening 161 for receiving the threaded end of a bolt 162 which may besunk in supporting floor 163. A nut 164 is threaded on bolt 162 tothereby tie the aligning rail 132 to the supporting surface 163 with theresilient seals 156 in sealing engagement therewith. An access opening165 may be provided in the portion 134 of aligning rail 132 to gainaccess to the nut 164 for tightening or loosening the same relative tobolt 162. It is to be understood that while the structure shown inFIGURE 20 has been described with relationship to tying the same to thefloor or a similar supporting surface, the same parts could function ingenerally the same manner for tying the structure to the underside of aceiling, roof, or the like.

FIGURE 21 illustrates the use of transom means 110 and aligning rail 122in tying a panel 147 to surface 166 which could be a supporting surfaceor ceiling or roof line. The side walls 147]) and 1470 of panel 147snugly embrace, in a force fit relationship, the exterior of the sidewalls 126a and 126b of the aligning rail 122. Aligning rail 122, inturn, snugly embraces the wall portions 114a, 116a and 114b, 116b,between its opposed stublike surfaces 130a, 128a and 13012, 128b,respectively. In this manner, the block-like panel 136 is securelyconnected to the transom means 110. In a similar fashion with respect tothat described in FIGURE 20 relative to the aligning rail 132, anopening 167 may be formed general- 1y centrally in the portion 112 ofthe transom 110 for receiving the shank of a bolt 168 which may be sunkin the supporting surface 166. A nut 169 threaded on the bolt 168 tiesthe transom member 110 to the surface 166 with the resilient seals 156in sealing engagement with the surface 166.

In FIGURE 22, the structure described in FIGURE 21 is shown abutting aroof line or ceiling 170 but the bolt 171 extends upwardly through thepanel 147 and is tied thereto by placement of a nut 172 on the top sideof portion 112 of the transom 110 so that the side wall is tied down toa slab such as 166- in which the bolt 171 may be anchored for resistinghigh wind and uplift forces, or the like.

The set of prefabricated wall elements disclosed herein may be utilizedto construct a complete wall structure or a closure bounded by aplurality of such walls, without the use of conventional fasteningmeans. If desired, as illustrated, the transom means located adjacent asupporting surface or roof line may be bolted thereto but otherwise,except for the provision of a door, or the attachment of a take-offrnullion for the offset wall, the entire wall structure, including thickdecorative and insulating panels, window frames and the like, may beassembled by inter-engagement of the several interfitting parts of themullions and transoms disclosed herein.

The foregoing detailed description has been given for clearness ofunderstanding only, and no unnecessary limitations should be understoodtherefrom, as some modifications may be obvious to those skilled in theart.

I claim:

1. A set of prefabricated wall mullion and transom elements for use incombination with prefabricated panels to form an interlockingprefabricated wall assembly, comprising: lock mullions having lockingsurfaces thereon for interlocking engagement with mating surfaces ofother mullions; said first panel retaining mullions including a largepanel retaining mullion having a base portion and two spaced wallsextending outwardly from opposite ends of the base portion constructedand arranged to receive the opposite outer walls of a panel therebetweenin a force fit relationship, said panel retaining mullion furtherincluding spaced locking fingers constructed and arranged forinterlocking engagement with the locking surfaces of the lock mullions;transom means constructed and arranged to engage a horizontal surfaceand being provided with means for retaining an upright wall segmentdefined by at least one panel retaining mullion, whereby a plurality ofsaid panel retaining mullions may be connected together as aprefabricated wall unit solely by means of interlocking engagement withsaid lock mullions.

2. A set of prefabricated wall mullion and transom elements for use incombination with prefabricated panels to form an interlockingprefabricated wall assembly, comprising: lock mullions having lockingsurfaces thereon for interlocking engagement with mating surfaces ofother mullions; first panel retaining mullions, said first panelretaining mullions including a large panel retaining mullion having abase portion and two spaced walls extending outwardly from opposite endsof the base portion constructed and arranged to receive the oppositeouter walls of a panel therebetween in a forced fit relationship, saidpanel retaining mullion further including spaced locking fingersconstructed and arranged for interlocking engagement with the lockingsurfaces of the lock mullions; transom means constructed and arranged toengage a horizonal surface and being provided with means for retainingan upright Wall segment defined by at least one panel retaining mullion;second panel mullions engageable with said first panel mullionsincluding a corner mullion having generally normally extending surfacesfor locking engagement with interlocking surfaces of said panelretaining members by means of said locking mullions for securing twosuch panel retaining members together disposed generally at right anglesto each other and masking the exteriorly facing adjacent surfacesthereof, whereby a plurality of said panel retaining mullions may beconnected together as a prefabricated wall unit solely by means ofinterlocking engagement with said lock mullions.

3. The set defined in claim 2 wherein said second mullions includes adoor jamb mullion which is constructed and arranged for force fitsecurement within the spaced side walls of the large panel retainingmullion.

4. The set defined in claim 2 wherein said second panel mullionsincludes a first end cover mullion having a base portion and two spacedside walls extending outwardly therefrom, said first end cover mullionside wall terminating in inwardly offset locking portions adapted to bematingly received between the side walls of said large panel retainingmullion with the side walls of both mullions generally coplanar witheach other.

5. The set defined in claim 2 wherein said remainder of said panelretaining mullions includes a second end cover mullion, said second endcover mullion having a base portion and two side walls extendingoutwardly from the same side of opposite ends of the base, said sidewalls being spaced apart substantially the same distance as said largepanel retaining mullion for matingly receiving therebetween such panelsand mullions as may be received by the side walls of said large panelmullion.

6. The set as defined in claim 2 wherein said remainder of said panelretaining mullions includes large panel common retaining mullion, beinggenerally H-shaped in plan and having a base portion and side wallsextending outwardly from both faces of opposite ends of the base, thedistance between each pair of opposite adjacent side walls beingsubstantially the same as the distance between the side walls of saidlarge panel retaining mullion for matingly receiving therebetween suchpanels and mullions as may be received between the side walls of saidlarge panel mullion.

7. The set as defined in claim 2 wherein said remainder of said panelretaining mullions includes a second window mullion including a panelreceiving surface flanked by spaced notches for connectably receivingpanel fastening mullions therein and spaced locking stubs extending fromthe side opposite said panel receiving surface, the outer surfaces ofsaid locking stubs being spaced apart a distance substantially equal tothe distance between said large panel mullion side walls for nesta-blymating between said large panel mullion side walls or other sets of sidewalls correspondingly spaced apart.

8. The set as defined in claim 2 including a takeoff mullion having agenerally planar base and spaced interlocking fingers on one facethereof substantially similar to the corresponding interlocking fingersof said window retaining mullions and said large panel retainingmullions for connection of said takeoff mullion therewith by means ofthe interlocking engagement with lock mullions.

9. The set as defined in claim 2 wherein said transom means includes ahorizontal aligning rail including a base portion, a mullion supportingportion spaced from said base portion for supporting thereon theinterlocking finger surfaces of said some panel retaining mullions, saidmullion supporting portion being joined to said base by intermediatewall means, spaced apart a distance sutficient to snugly nest betweensaid interlocking finger portions, and spaced leg portions connected tosaid mullion supporting portion for engaging a horizontal surface of abuilding structure to hold a panel retaining mullion adjacent ahorizontal building member.

10. The set as defined in claim 2 wherein said transom means includes alarge panel head transom member having a generally U-shapedconfiguration and including a base portion and spaced outwardlyextending side walls, the distance between the outer surfaces of saidside walls being substantially the same as the distance between theinterior of the side walls of said large panel retaining mullion, saidlarge panel head transom member including spaced stubs projectingoutwardly from the base slightly inwardly from said side walls, the endsof said side walls being inturned and terminating in stubs generallyaligned with said base stubs.

11. The set as defined in claim 2 wherein said transom means alsoincludes a horizontal rail including a base, spaced feet extending fromone side of said base for engagement with a horizontal surface of abuilding structure, and upright walls at opposite ends of the base, theexterior of said walls being spaced apart a distance substantially thesame as the distance between the stubs of said panel head transom memberfor supporting said panel head transom member thereon in snug matingengagement therewith.

References Cited UNITED STATES PATENTS 3,057,444 10/1962 Walberg 524763,072,226 1/ 1963 Hardwood 52-281 3,173,179 3/1965 Edwards 52-207REINALDO P. MACHADO, Primary Examiner.

US. Cl. X.R. 52281, 476, 495

